US8280647B2 - Method and system for monitoring process states of an internal combustion engine - Google Patents

Method and system for monitoring process states of an internal combustion engine Download PDF

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US8280647B2
US8280647B2 US12/480,411 US48041109A US8280647B2 US 8280647 B2 US8280647 B2 US 8280647B2 US 48041109 A US48041109 A US 48041109A US 8280647 B2 US8280647 B2 US 8280647B2
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combustion chamber
determining
mass flow
exhaust gas
educts
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US20090281737A1 (en
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Konrad Stadler
Andreas Poncet
Thomas von Hoff
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ABB Research Ltd Switzerland
ABB Research Ltd Sweden
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ABB Research Ltd Switzerland
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02C—GAS-TURBINE PLANTS; AIR INTAKES FOR JET-PROPULSION PLANTS; CONTROLLING FUEL SUPPLY IN AIR-BREATHING JET-PROPULSION PLANTS
    • F02C9/00—Controlling gas-turbine plants; Controlling fuel supply in air- breathing jet-propulsion plants
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D17/00—Regulating or controlling by varying flow
    • F01D17/02—Arrangement of sensing elements
    • F01D17/08—Arrangement of sensing elements responsive to condition of working-fluid, e.g. pressure
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02C—GAS-TURBINE PLANTS; AIR INTAKES FOR JET-PROPULSION PLANTS; CONTROLLING FUEL SUPPLY IN AIR-BREATHING JET-PROPULSION PLANTS
    • F02C7/00—Features, components parts, details or accessories, not provided for in, or of interest apart form groups F02C1/00 - F02C6/00; Air intakes for jet-propulsion plants
    • F02C7/04—Air intakes for gas-turbine plants or jet-propulsion plants
    • F02C7/057—Control or regulation
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02D—CONTROLLING COMBUSTION ENGINES
    • F02D41/00—Electrical control of supply of combustible mixture or its constituents
    • F02D41/0002—Controlling intake air
    • F02D41/0007—Controlling intake air for control of turbo-charged or super-charged engines
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02D—CONTROLLING COMBUSTION ENGINES
    • F02D41/00—Electrical control of supply of combustible mixture or its constituents
    • F02D41/02—Circuit arrangements for generating control signals
    • F02D41/14—Introducing closed-loop corrections
    • F02D41/1438—Introducing closed-loop corrections using means for determining characteristics of the combustion gases; Sensors therefor
    • F02D41/1444—Introducing closed-loop corrections using means for determining characteristics of the combustion gases; Sensors therefor characterised by the characteristics of the combustion gases
    • F02D41/1445—Introducing closed-loop corrections using means for determining characteristics of the combustion gases; Sensors therefor characterised by the characteristics of the combustion gases the characteristics being related to the exhaust flow
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02D—CONTROLLING COMBUSTION ENGINES
    • F02D41/00—Electrical control of supply of combustible mixture or its constituents
    • F02D41/02—Circuit arrangements for generating control signals
    • F02D41/14—Introducing closed-loop corrections
    • F02D41/1438—Introducing closed-loop corrections using means for determining characteristics of the combustion gases; Sensors therefor
    • F02D41/1444—Introducing closed-loop corrections using means for determining characteristics of the combustion gases; Sensors therefor characterised by the characteristics of the combustion gases
    • F02D41/1446—Introducing closed-loop corrections using means for determining characteristics of the combustion gases; Sensors therefor characterised by the characteristics of the combustion gases the characteristics being exhaust temperatures
    • F02D41/1447—Introducing closed-loop corrections using means for determining characteristics of the combustion gases; Sensors therefor characterised by the characteristics of the combustion gases the characteristics being exhaust temperatures with determination means using an estimation
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02D—CONTROLLING COMBUSTION ENGINES
    • F02D41/00—Electrical control of supply of combustible mixture or its constituents
    • F02D41/02—Circuit arrangements for generating control signals
    • F02D41/18—Circuit arrangements for generating control signals by measuring intake air flow
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02D—CONTROLLING COMBUSTION ENGINES
    • F02D2200/00—Input parameters for engine control
    • F02D2200/02—Input parameters for engine control the parameters being related to the engine
    • F02D2200/10—Parameters related to the engine output, e.g. engine torque or engine speed
    • F02D2200/1002—Output torque
    • F02D2200/1004—Estimation of the output torque
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02D—CONTROLLING COMBUSTION ENGINES
    • F02D41/00—Electrical control of supply of combustible mixture or its constituents
    • F02D41/02—Circuit arrangements for generating control signals
    • F02D41/14—Introducing closed-loop corrections
    • F02D41/1438—Introducing closed-loop corrections using means for determining characteristics of the combustion gases; Sensors therefor
    • F02D41/1444—Introducing closed-loop corrections using means for determining characteristics of the combustion gases; Sensors therefor characterised by the characteristics of the combustion gases
    • F02D41/1446—Introducing closed-loop corrections using means for determining characteristics of the combustion gases; Sensors therefor characterised by the characteristics of the combustion gases the characteristics being exhaust temperatures
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02D—CONTROLLING COMBUSTION ENGINES
    • F02D41/00—Electrical control of supply of combustible mixture or its constituents
    • F02D41/02—Circuit arrangements for generating control signals
    • F02D41/14—Introducing closed-loop corrections
    • F02D41/1497—With detection of the mechanical response of the engine
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2260/00—Function
    • F05D2260/80—Diagnostics
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2270/00—Control
    • F05D2270/30—Control parameters, e.g. input parameters
    • F05D2270/303—Temperature
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/10—Internal combustion engine [ICE] based vehicles
    • Y02T10/12—Improving ICE efficiencies

Definitions

  • the present disclosure relates to the field of control and instrumentation technology for internal combustion engines, and/or for rotating machines.
  • Exemplary embodiments relate to methods and systems for monitoring process states of a rotating machine with a combustion chamber, including turbo machines such as gas turbines.
  • GPA Gas Path Analysis
  • a maintenance action schedule is deduced, for ensuring economic and safe operation, or a prediction of the remaining life of the major components is made.
  • the origin of a fault affecting a given component of the gas turbine can be of various natures, such as a contamination of compressor blades, erosion of turbine blades or corrosion of machine parts, for example. Conversely, different faults often create similar observable effects or degradation symptoms.
  • the turbine inlet temperature is constrained to an upper limit, as high temperatures let the turbine blades deteriorate faster than lower temperatures, thereby reducing the life time of the GT.
  • high temperatures are desired. Therefore, the turbine inlet temperature is controlled tightly.
  • the turbine inlet temperature is not measured but derived from other measurable states, which can produce uncertainty on the controlled variable. Reliable methods to derive turbine inlet temperatures are therefore desired for operating a GT efficiently. Precise knowledge of these unmeasured states makes it possible to better estimate the operating conditions and, therefore, to better predict maintenance scheduling.
  • Model-based techniques make use of Kalman filter techniques for the online estimation of the unknown states or use iterative methods (e.g. Newton-Raphson), such as described in EP 1 233 165.
  • iterative methods e.g. Newton-Raphson
  • these methods can be impacted negatively in that the fluid flowing through the GT can influence considerably the unmeasured states, e.g. ambient humidity (in form of vapour) cools the turbine inlet temperature owing to the vaporization energy. Often this effect is compensated by applying empirical correction curves.
  • This effect is also used to lower the temperature in the combustion chamber in order to reduce NO X emission when the GT is operated with liquid fuel (oil) instead of gaseous fuel.
  • the combustion is not modelled and, therefore, the composition of air (influenced by the ambient humidity) and of the exhaust gas (influenced by fuel and air composition) and the corresponding mass flows are not considered.
  • a method is disclosed of monitoring at least one process state of an internal combustion engine having a combustion chamber, the method comprising: measuring compositions of educts (m a , m f ) entering a combustion chamber; determining, based on the compositions of the educts (m a , m f ), a composition of a product produced by the combustion chamber; determining mechanical power (P mech ) generated by the internal combustion engine; and determining a value of at least one process state based on the mechanical power (P mech ), the composition of the educts ( m a , m f ) and product, and stoichiometric relationships of educts and product.
  • a system for monitoring at least one process state of an internal combustion engine having a combustion chamber, the system comprising: means for measuring compositions of educts ( m a , m f ) entering the combustion chamber; means for determining based on the compositions of the educts ( m a , m f ) a composition of a product produced by the combustion chamber; means for determining mechanical power (P mech ) generated by the internal combustion engine; and means for determining a value of at least one process state based on the mechanical power (P mech ), the composition of the educts ( m a , m f ) and product, and stoichiometric relationships of educts and product.
  • FIG. 1 shows an exemplary block diagram illustrating schematically a gas turbine and exemplary process states
  • FIG. 2 shows a block diagram illustrating schematically exemplary thermodynamic boundaries of a gas turbine
  • FIG. 3 shows an exemplary sequence of steps for monitoring process states of a rotating machine having a combustion chamber
  • FIG. 4 depicts exemplary compound enthalpies for four distinct gas compositions
  • FIG. 5 depicts an exemplary manner by which a turbine inlet temperature is determined from an enthalpy line.
  • a method and a system are disclosed for monitoring unmeasured process states of an internal combustion engine, for example of a rotating machine having a combustion chamber such as a turbo machine (e.g., a gas turbine).
  • a turbo machine e.g., a gas turbine
  • Exemplary embodiments of the present disclosure can provide a method and a system for determining more accurately than with known methods the turbine inlet temperature of a gas turbine.
  • Exemplary embodiments of the present disclosure can determine unmeasured process states such as air mass flow, exhaust gas mass flow and turbine inlet pressure, for assessing efficiency of the gas turbine.
  • exemplary embodiments are provided for monitoring (unmeasured) process states of a rotating machine having a combustion chamber, and measuring compositions of educts entering the combustion chamber. Based on the compositions of the educts, the composition of the product produced by the combustion chamber can be determined. Moreover, the mechanical power generated by the rotating machine can be determined. For example, the mechanical power can be determined based on characteristics of a generator driven by the rotating machine and based on the measured power generated by the generator. Based on the mechanical power, the composition of the educts and product, and stoichiometric relationships of educts and product, the value of at least one of the process states can be determined and, for example, displayed and/or provided to a control unit controlling the rotating machine.
  • the product i.e. the composition of the exhaust gas
  • various unmeasured process states can be determined (e.g. the air mass flow through the compressor leading into the combustion chamber and/or a gas mass flow, a composition and/or a temperature of exhaust gas exiting the combustion chamber). For example, in addition to monitoring unmeasured process states (e.g.
  • the proposed exemplary method and system are applicable to any rotating machinery where combustion is involved (e.g. a gas turbine, a diesel engine, an internal combustion engine, etc.).
  • the air mass flow through the compressor leading into the combustion chamber can be determined.
  • the gas mass flow of exhaust gas exiting the combustion chamber can be determined.
  • the composition of the exhaust gas can be determined.
  • the temperature of the exhaust gas exiting the combustion chamber can be determined. The temperature of the exhaust gas exiting the combustion chamber can be representative of the inlet temperature of the turbine that is driven by the exhaust gas exiting the combustion chamber.
  • Temperatures of educts and product can be measured, and, based on their respective temperatures, enthalpies for educts and product can be determined using enthalpy functions associated with their respective compositions.
  • measured are the temperatures of air and fuel entering the combustion chamber, and the temperature of the exhaust gas exiting the turbine.
  • enthalpies for air, fuel and exhaust gas can be determined based on their respective temperatures, and the value of the at least one of the process states is based on the enthalpies.
  • an inverted enthalpy function associated with the composition of the exhaust gas can be determined. Subsequently, the temperature of the exhaust gas exiting the combustion chamber is determined based on the air mass flow and the gas mass flow using the inverted enthalpy function.
  • FIG. 1 shows exemplary principal components of a rotating machine 2 , particularly a gas turbine, viewed as a system comprising (e.g., consisting of) a sequential arrangement of ideal volume elements in thermodynamic equilibrium, i.e. compressor inlet 2 a (filter, nozzle), compressor 2 b , combustion chamber 2 c , turbine 2 d and outlet conduit 2 e , wherein compressor 2 b and turbine 2 d are mechanically interconnected by a shaft 2 f .
  • FIG. 1 also depicts the places where the various dependent or system output variables, i.e. the process variables such as temperatures, pressures, power and shaft speed, are measured.
  • indices a, f, g, and w refer to air, fuel, exhaust gas, or water, respectively.
  • reference numerals w a , w f , w g , w w refer to air mass flow, fuel mass flow, exhaust gas mass flow, or water mass flow, respectively
  • reference numerals m a , m f , m g , m w refer to the specific compositions of air, fuel, exhaust gas, or water, respectively
  • reference numerals h a , h f , h g refer to the enthalpy at specific temperatures T i of air, fuel, or exhaust gas, respectively.
  • the main unmeasured process states can be used to monitor and/or control efficient operation include the turbine inlet temperature T 3 , the air mass flow w a , and the exhaust gas mass flow w g .
  • the turbine inlet pressure p 3 can also be determined.
  • the exhaust gas composition may be of interest for regulatory reasons (e.g. CO 2 emission).
  • FIG. 2 shows schematically the thermodynamic system boundaries 2 ab , 2 de of the gas turbine, boundary 2 ab encompassing compressor inlet 2 a and compressor 2 b , and boundary 2 de encompassing turbine 2 d and outlet conduit 2 e.
  • the losses can be quantified with sufficient accuracy and can be combined and described by one power term P loss which is assumed to be known.
  • the mechanical power P mech generated by the turbine 2 d can be derived, for example, from the generator characteristics and the measured generator power P gen . Using the system boundaries as defined in FIG.
  • h ( ⁇ ) (T ( ⁇ ) ) The enthalpies for air, fuel and exhaust gas, h ( ⁇ ) (T ( ⁇ ) ), can be derived by considering their specific composition m ( ⁇ ) and by using the enthalpy functions h ( ⁇ ) (T ( ⁇ ) ) published by NASA as polynomials which describe the enthalpy of the main elements.
  • the polynomials are taken from http://cea.grc.nasa.gov/, which is a tool provided by the NASA Glenn Research Center under the title “Chemical Equilibrium with Applications”.
  • FIG. 4 depicts examples of compound enthalpies h(T) for four distinct gas compositions, as obtained from the NASA site.
  • the terms w g ⁇ [h g (T 3 ) ⁇ h g (T 4 )] and w a are unknown, as w g , T 3 and m g are unknown.
  • w a is derived.
  • the product w g h g (T 3 ) is calculated from the enthalpies that enter the combustion process.
  • w g ⁇ h g ( T 3 ) w a ⁇ h a ( T 2 )+ w f ⁇ h f ( T f )+ w f ⁇ h f .
  • the vector M contains the corresponding molar masses and diag( M ) is a matrix with the elements of M on its diagonal.
  • the first row in V can be read as the amount of O 2 molecules in the educt minus two times amount of CH 4 molecules minus 2.5 times the amount of C 2 H 6 molecules yields the amount of O 2 molecules in the product.
  • the second row reads as the amount of CO 2 in the educt plus once the amount of molecules of CH 4 plus twice the amount of molecules of C 2 H 6 yields the CO 2 amount in the product.
  • w a P mech + P loss - w f ⁇ ( h f ⁇ ( T f ) + ⁇ ⁇ ⁇ h f - ( V ⁇ m _ f ) T ⁇ h ⁇ ( T 4 ) ) h a ⁇ ( T 0 ) - m _ a T ⁇ h _ ⁇ ( T 4 ) ( 12 )
  • m _ g V ⁇ w a ⁇ m _ a + w f ⁇ m _ f w a + w f ⁇ ⁇ w g , ( 14 )
  • T 3 h g - 1 ⁇ ( w a ⁇ h a ⁇ ( T 2 ) + w f ⁇ h f ⁇ ( T f ) + w f ⁇ ⁇ ⁇ ⁇ h f w a + w f ) . ( 13 )
  • the inversion is schematically depicted in FIG. 5 , where (due to monotonicity) the temperature T 3 is found corresponding to a particular enthalpy.
  • Five distinct enthalpy lines for constant exhaust gas compositions are depicted (broken lines), one of them being approximated by a 2 nd order polynominal h′ g in the relevant temperature range between 1000 and 1500 K (shaded area).
  • the interpolating low order polynomials are inverted for the purpose of deriving T 3 .
  • the method is implemented, for example, on an industrial control system 1 for monitoring the unmeasured process states and/or for controlling the turbine inlet temperature T 3 . Due to the fact that the combustion is taken into account, CO 2 emissions can be derived directly through the calculation. Furthermore, the method can be extended for supervising the quality of fuel input. Properties of specific gas components, such as CO 2 or NO x , are often measured in the exhaust gas for regulatory reasons. Having available both, a measurement and an estimation (based on the above determination), provides information on the quality of combustion, quality of fuel input and/or sensor failure, leading to enhanced diagnostics of the combustion system.
  • the system 1 comprises a sensor module 11 for receiving measurements of process variables and/or educt composition(s); a data and program memory 12 for storing measurement values, calculation parameters and programmed software modules; a processing unit 13 with at least one processor; and an output module 14 for displaying processing states and/or for proving, to the gas turbine 2 or to a control unit controlling the gas turbine 2 , control signals based on the derived processing states.
  • the program memory 12 comprises a programmed software module for controlling the processing unit such that the method is executed as described in the following paragraphs with reference to FIG. 3 .
  • step S 1 measurements are taken and respective measurement values are received by sensor module 11 and stored in the system 1 .
  • step S 2 the processing unit 13 computes the air mass flow w a using equation (12), as described above.
  • step S 3 the processing unit 13 computes the exhaust gas mass flow w g and exhaust gas composition m g using equations (13) or (14), respectively.
  • step S 4 the processing unit 13 computes the enthalpy inversion h g ⁇ 1 .
  • step S 5 the processing unit 13 computes the turbine inlet temperature T 3 using equation (15) as described above.
  • the computer process states e.g. the air mass flow w a , the exhaust gas mass flow w g , the exhaust gas composition m g , and/or the turbine inlet temperature T 3 , are used by the output module 14 for applications of performance evaluation A 1 , combustion/emission control A 2 , and/or turbine control A 3 .

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Control Of Turbines (AREA)
  • Engine Equipment That Uses Special Cycles (AREA)
  • Supercharger (AREA)
  • Testing Of Engines (AREA)
  • Combined Controls Of Internal Combustion Engines (AREA)
US12/480,411 2006-12-07 2009-06-08 Method and system for monitoring process states of an internal combustion engine Expired - Fee Related US8280647B2 (en)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
EP06405509.8 2006-12-07
EP06405509A EP1930568B1 (en) 2006-12-07 2006-12-07 Method and system for monitoring process states of an internal combustion engine
EP06405509 2006-12-07
PCT/EP2007/063518 WO2008068330A1 (en) 2006-12-07 2007-12-07 Method and system for monitoring process states of an internal combustion engine

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EP (1) EP1930568B1 (es)
CN (1) CN101595288B (es)
AT (1) ATE474133T1 (es)
DE (1) DE602006015490D1 (es)
ES (1) ES2347345T3 (es)
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US11739696B2 (en) * 2021-12-13 2023-08-29 Pratt & Whitney Canada Corp. System and method for synthesizing engine output power
JP2023166083A (ja) * 2022-05-09 2023-11-21 三菱重工業株式会社 ガスタービン制御装置、ガスタービン制御方法、及びプログラム

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ES2347345T3 (es) 2010-10-28
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CN101595288A (zh) 2009-12-02
WO2008068330A1 (en) 2008-06-12
US20090281737A1 (en) 2009-11-12
DE602006015490D1 (de) 2010-08-26
ATE474133T1 (de) 2010-07-15
EP1930568A1 (en) 2008-06-11

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